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<p>This study centered on the grinding mechanism of large spiral angle groove grinding wheels (LSG-GW), aiming to analyze the root causes of “mapping effect” in high-performance alloy high-surface integrity machining and reveal the evolution law of dynamic grinding forces, so as to solve the problems of local high temperature and burnishing stem from the low heat transfer efficiency in the grinding arc area in traditional precision grinding. During the research process, theoretical models at both macroscopic and microscopic levels were constructed for the study. At the macroscopic level, the grinding wheel was discretized along both axial and circumferential directions with spiral geometric parameters defined, and a cycloid kinematics model was established to quantify the influence of the groove structure on the workpiece surface ridges. At the microscopic level, a random polygon abrasive distribution model and an encircling sphere collision method were used to eliminate abrasive overlapping, and an abrasive cutting edge model was constructed to simulate the actual surface morphology of the grinding wheel. A dynamic grinding model of LSG-GW was developed. This model introduced an elastic–plastic contact critical depth and analyzed the relevant mechanisms between the instantaneous undeformed chip cross-sectional area and the dynamic grinding force based on a discrete point array. The research results showed that process parameters had a significant impact on the mapping effect: the workpiece feed rate and groove width were positively correlated with the ridge height, while the grinding wheel speed and diameter were negatively correlated with the ridge height. Compared with ordinary grinding wheels, the grinding force of LSG-GW could be reduced by 15%-20%, which significantly improved the surface integrity of the workpiece. In this study, suppression strategies against the mapping effect and an empirical formula for dynamic grinding forces were proposed. After verification, the error between the simulation results and the experimental data was less than 10.92%, thereby confirming the model’s reliability. This study enhanced the understanding of the structured grinding wheel interface mechanism, provided a theoretical basis for high-performance alloy grinding processes focused on efficient shape control and performance control, and effectively promoted the advancement of high-performance alloy precision machining technology.</p>

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Study on the grinding mechanism of large spiral angle grooved wheels for enhancing surface integrity of high-performance alloys

  • 期刊论文

  • 发表日期：

    2025年6月17日

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  • Xuekun Sun,
  • Jingliang Jiang,
  • Quanrong Fu,
  • Na Wang,
  • Tianxu Chen

摘要

This study centered on the grinding mechanism of large spiral angle groove grinding wheels (LSG-GW), aiming to analyze the root causes of “mapping effect” in high-performance alloy high-surface integrity machining and reveal the evolution law of dynamic grinding forces, so as to solve the problems of local high temperature and burnishing stem from the low heat transfer efficiency in the grinding arc area in traditional precision grinding. During the research process, theoretical models at both macroscopic and microscopic levels were constructed for the study. At the macroscopic level, the grinding wheel was discretized along both axial and circumferential directions with spiral geometric parameters defined, and a cycloid kinematics model was established to quantify the influence of the groove structure on the workpiece surface ridges. At the microscopic level, a random polygon abrasive distribution model and an encircling sphere collision method were used to eliminate abrasive overlapping, and an abrasive cutting edge model was constructed to simulate the actual surface morphology of the grinding wheel. A dynamic grinding model of LSG-GW was developed. This model introduced an elastic–plastic contact critical depth and analyzed the relevant mechanisms between the instantaneous undeformed chip cross-sectional area and the dynamic grinding force based on a discrete point array. The research results showed that process parameters had a significant impact on the mapping effect: the workpiece feed rate and groove width were positively correlated with the ridge height, while the grinding wheel speed and diameter were negatively correlated with the ridge height. Compared with ordinary grinding wheels, the grinding force of LSG-GW could be reduced by 15%-20%, which significantly improved the surface integrity of the workpiece. In this study, suppression strategies against the mapping effect and an empirical formula for dynamic grinding forces were proposed. After verification, the error between the simulation results and the experimental data was less than 10.92%, thereby confirming the model’s reliability. This study enhanced the understanding of the structured grinding wheel interface mechanism, provided a theoretical basis for high-performance alloy grinding processes focused on efficient shape control and performance control, and effectively promoted the advancement of high-performance alloy precision machining technology.